Sound horn



June 9, 1931. J. a. HAWLEY 1,809,035

SOUND HORN Filed July 8. 1927 3 Shuts-Sheet l III III I June 9, 1931. 5,HAwLEY 1,809,035

SOUND HORN Filed July s, 1927 3 shuts-sheet 2 June 9, 1931.

J. B. HAWLEY 1,809,035

SOUND HORN Filed July 8. 1927 s studs-sheet a Patented June 9, 1931PATENT! OFFICE JESSE BABNUM HAWLEY, OF ST. CHARLES, ILLINOIS scum) nomwApplication filed July 8, 1927. Serial No. 204,402.

The present invention relates to sound horns or the like and the methodof making such. a

Among the objects of the invention is to 53 provide a novel sound hornor sound amplier having a hollow sound conveyin member or passageembedded in a mass solidified material which may be applied about thehorn parts, such as the tone arm thereof 1 or the same and partlyorwholly about or around the bell of, the horn, as by pouring solidifiablematerial about and around the parts of the horn, such material hardeningor solidifying about such parts, together with the same forming aunitary sound amplifying device. The solidifiable or filling materialsof different or various densities, gravities or solidities may be usedin making such horns. As for example, material of greater density may beapplied around the smaller portion of the tone arm and material of lessdensity may be applied around the larger portion of the tone arm. Inthis way different degrees of rigidity may be had in the unit asdesired, as well as varying the weight of such unit.

Another object of the invention is to provide a novel horn of long aircolumntype and with the hollow sound conveying memher or passagecomposed of a series of hollow members, or sections or segments whichmay be arranged and connected together in series, with-or Without thesolidifiable material therearound. Preferably the series is of tortuousform so that the passage may be located in a space of small compasswithout sacrificing the advantages of a long air column. Each sectionmay be curved or partly straight and partly curved. The passage, whetherproduced from a series of hollow sections or is a single integralmember, may be composed of fibrous material and in accordance with theprocess disclosed in my Patent No. 1,624,242, granted April 12, 1927.The sections may be connected together at adjoining ends by any suitablemeans, such as paper, tape and other similar means. By making thepassage in sections, easier handling of the parts when 50 building thehorn is made possible, as also providing for more accurate dimensions.The sections of smaller diameter are preferably thicker than thesections of larger diameter.

As another feature of the invention, the making of the device with ahollow passage embedded in solidifiable material, provides for the useof thinner walls of the passage than has heretofore been possible, thusreducing the cost and time of manufacture as well as eliminating theaccuracy necessary when joining the section ends of parts of a hornwhich is designed to be self-sustaining. The solidified material aboutthe passage will rigidly hold the parts in shape and in place as also infixed relation to each other. By making the passage of fibrous material,the advantages peculiar to suchmaterial in the acoustical rendition ofthe horn may be retained, yet the dissipation of sound energy by reasonof vibration of the passage walls will be eliminated or prevented owingto the giving of rigidity to such walls by the adhering solidifiedsurrounding mass of material. Preferably the bell of the horn may beonly partly embedded so that it may have sufficient vibration orresonance to avoid cistern sounds, although in some cases, the bell maybe wholly embedded as in the case of the tone arm. The weight of theunit may be varied by choice of material of given density, as also bythe shape of the block thereof when solidified. A much longer and moreaccurately made horn can be constructed in this way in a given space,the use of short sections aiding to this end. Because of the use of thinwalls, particularly when made of fibrous material, a more rapid dryingthereof may be effected, thus omitting the time required in dryingthicker walled parts of such material. The drying may 'be effected inthe poured material when the latter is poured hot and which solidifieson cooling, as in the case of several sulphur and like compounds.

The invention also comprehends a novel process or method of making theabove mentioned horn.

Other objects, advantages, capabilities and features are comprehended bythe insame with parts shown in dotted line projections.

Fig. 3 is a sectional view of the horn in the process of applyingsolidifiable material around the horn parts 4 Fi 4 is a view similar to1 of a di erent form of horn. i Fig. 5 is a sectional view through afurther or alternate form of horn and showing the step of applyingsolidifiable material therearound.

Fig. 6 is a vertical sectional view of the same in completed form.

Fig. 7 v is a fragmentary view of the device showin the solidifiedmaterial with a part omitte for reducing weight.

Fig. 8 is a perspective view of another form of horn without surroundingsolidified material.

Fig. 9 is a view in vertical elevation of the same from the bell sidethereof.

Fig. 10 is a sectional view of a horn showing the mode of applyingsolidifiable material around the parts thereof.

And, Fig. 11 is a sectional-view of the same in completed condition.

Referring now more in detail to the drawings, the embodiments selectedto illustrate the invention are shown of drum type as illustrated inFigs. 1to 6 inclusive, and

of rectangular or polygonal form as shown in Figs. 7 to 10 inclusive.

Inthe drum type of horn, the sound conveying passage is composed of aseries of hollow members 1, 2,3 and 4 of exponential form and with theadjoining ends of the parts held connected together by means of suitablewrappers, tape elements or the like 5, 6 and 7 as clearly shown in Fig.2 of the drawings. To the smaller end 8 of the member 1 may be attachedthe loud speaking unit adapted to generate or reproduce sound. To thelarger end of the part or member 4 may be connected'a hell 9 or thelike. The hollow members are connected and arranged in a more or lesstortuous arrangement or disposition so that the whole sound passage withthe bell may be nested in a small space or compass as clearly shown inthe drawings.

The passage sections or members 1, 2, 3 and 4, as well as the bell part9 may be made of fibrous material in accordance with the processdisclosed in my above mentioned patent. In this construction, the wallsof the passage may be made much thinner than that disclosed in the aboveindicated patent,.and if desired, the member 1 may .be made with thickerwalls than the succeeding members 2, 3 and 4. it not being required tohave thick walls in this construction, for a reason later to beexplained. Preferably, section 1 has thicker walls than section 2, andthe latter thicker than sections 3 and 4, the preceding section of anysection of the series being subjected to greater sound pressures.

. With these parts assembled as above mentioned, the assembly may thenbe placed inside of an enclosing envelope or shell 10 which ispreferably placed upon a table 11 or the like. The horn maybe locatedtherein with the smaller end 8 extending into a recess portion 12 at oneside of the shell 10, and with the flange 13 of the bell resting uponthe flange 14 of the shell. It

will be noted that the horn assembly is included wholly within the spaceor confine of the shell 10, as clearly shown in Fig. 3. With the partsthus positioned, filling material or solidifiable substances 15 may thenbe applied thereto as by use of a trowel or by pouring into the shell 10until the latter is substantially filled as clearly shown in Fig. 3. Toreduce weight, the space may not be completely filled but, a hollow 15ain the block of solidified material left, as clearly shown in Fig. 7.This filling material 15 completely surrounds the various parts of thehorn and adheres thereto so as to rigidly hold the walls thereof in suchmanner that the filling material together with the embedded horn partsform a single unitary construction. The material 15 when solidifiedforms a block or a more less or solid member in which the horn itself.is embedded or enclosed. The shell 10 may be of various desi s asdesired, with ofi'set portions 16 whic may perform the function ofholding or locking the block construction so as to appearin the form ofa drum in the finished product.

When the material 15 has solidified, a grid or screen device 17 havingflanges 18 may be connected to the reduced part 19 of the bell, thescreen or grid 17 serving the purpose of hiding the opening in the bell,and likewise a rear cover or cap 20 having a flange 21 may be connectedto the reduced part 22 at the rear of the shell 10, as clearly shown inFig. 4 of the drawings. To the socket portion 12 of the shell may beattached a pedestal or foot piece or base 23 also as clearly shown in Fi4.

In the method disclosed in the above patent, the fibrous material isfelted u on a former and later dried. By reason 0 making the walls ofthinner material than in the patent referred to, and also by reason ofthe fact that the material 15 adheres thereto when solidifying, it ispossible to make the sound passage with thin walls. These walls may beapplied in place and the material poured therearound before the same isdry, especially in the case of where the material is applied or pouredhot and solidifies when cooling. The" heat of the material will theneffect the drying of the walls of the sound passage withoutnecessitating the step or steps of pre-drying as in the case disclosedin the patent above mentioned.

The structures shown in Figs. 1 and 4 are alike with the exception thatthe shell 10 of Fig. 4 and 10a of Fig. 1 are of slightly different form,but being regarded as fully equivalent of each other. The final productis of general drum form and may stand by itself upon the base 23 withoutany ad ditional supporting means. The base 23 is preferably hollow tocontain the loud speaking unit which is preferably attached to thethreaded end 24 of the socket portion 12 of the shell, the smaller end 8of the member 1 fitting closely in the socket'member 12.

In the form shown in Figs. 5 and 6 the bell 25 is made larger than thebell 9 of the previous form and has an outwardly extending portion 26 asclearly shown. In this case the shell 27 may have'a flange portion 28that fits about the bell portion 26 and although the whole structure mabe supported by way of the flange 29 o the bell upon a table 11, it mayalso be supported in a different way by suitable supporting elements 30having feet 31 resting upon the table and arms 32 engaging with a flangeor surface portion 33 of the shell, thus supporting the whole structureby way of the shell instead of by way of the bell. Supporting blocks 30amay also be placed on the table and under the edge of the bell mouth tosupport the bell in order that it may not part from the shell, but thegreat majority of the weight of the whole device is sustained throughthe supporting elements 30 and the shell 10 or 10a. In other respects,the horn and solidified material is constructed as above described inconnection with the construction shown in Figs. 1 to 4 inclusive.

In the form of horn shown in Figs. 8 to 11 inclusive, the sound passageis composed of hollow portions 34, 35, 36 and 37 and a bell 38, thisstructure being of generally rectangular formation in cross-section andadapted for use in a cabinet or the like. The portions or members 34,35, 36 and 37 may be connected together in series as in the drum type ofdevice and with suitable connecting means such as paper wrappings,

'tapings, and the like, 39, 40 and 41 at the joints between the tone armsections or hollow members. It will be noted that the tone arln is bentor wound in tortuous form so that the whole sound passage including thebell may be disposed in a compact rectangular space. The members 34, 35,36 and 37 and the bell 38 may be made in accordancewith the processdisclosed in the 'patent "above indicated. The same may also be madeintegral without joints if desired, but it is more convenient to makethese parts separate and then to join them together toithe particulararrangement desired. This horn, as also in the case of the drum type,may be used without filling or solidifying material, in which case thewalls of the tone arm and bell will be thicker tllitl in the case whenthe fillingmaterial is use In the event of making the horn with fillingmaterial, the parts may be made with thinner walls and connectedtogether in the same way as described above in the drum typeconstruction. The same is then placed upon a table 41 with the bell 38thereof resting upon the top surface of the table. An enclosingenvelope, casing or such 42 made of suitable material, may then beconnected to the horn in such a way that a flange 43 thereof may restupon the horn and may also have a recess 44 in which the smaller end ofthe tone arm may extend, as clearly shown in Figs. 10 and 11 of thedrawings. The filling material 45 may then be applied within the shell42 and around and in between. the parts of the horn including a portionof the bell except the portion extending out beyondthe shell flange 43,as clearly shown in Figs. 10 and 11. In this way the portions of thehorn may be embedded, with the solidified material adhering to the wallsof the sound passage and forming with it a unitary rigid structure.Theshell 42 may be of any desired form or shape, and as shown, may be ofrectangular form so that it may be easily placed in a cabinet with themouth of the bell opposite the grid or screen in'the front of thecabinet.

In the various forms described and shown, the enveloping shell or casingfor the block of solidified material and embedded horn, may be of anysuitable material, such as metal, cardboard, composition or even fibrousmaterial and other like and similar substances.

In the construction shown in Figs. 8 to 11 inclusive the tone arm parts34, 35, 36 may be partly straight and partly curved, the curved portionsacting to reflect the conveyed sound at the curves or bends as alsoaiding in being able to place the parts in a small space or compass. Asshown in Fig. 8 the walls of the bell may be formed such that the upperand side walls 46, 47 and 48 may be convex and the lower wall concave,such that when the sound is being emitted from the sound within thedrum, the lower wallmay direct such sound toward the floor of the roomsuch that the floor of the room may act as a continuation of such wallfor the reflection of the sound.

While in Fig. 10 is shown a method of supplying the solidifiablematerial with the bell resting upon'the table 4]., it Wlll be understoodthat the invention comprehends the use of supporting elements such asthat shown in Fig. 5 capable of resting upon the table and engaging withthe underside of the casing or shell 42 to support the structure by wayof the shell rather than wholly by means of the flange or mouth of thebell 38, blocks 30a also being used to give the necessary support to thebell to prevent its sep ar'ating from the shell.

While I have herein the drawings shown a few illustrative embodiments ofthe invention, it is to be understood that the latter is not limitedthereto but may comprehend other constructions, details, arrangements ofparts, features and other method and process steps without departingfrom the spirit thereof. f

Havmg thus disclosed the invention. I claim:

1. A sound horn having a hollow sound member, and solidified material inwhich said member is embedded.

2. A sound horn having a sound passage composed of connected exponentialhollow units, and a block of solidified material in which said units areembedded.

3. A sound horn comprising a tone arm,

a bell, and a solidified mass of material in which said tone arm isembedded.

4. A sound horn comprising a tone arm, a bell, and a solidified mass ofmaterial in which said tone arm and a portion of said bell are embedded.

5. A sound horn having a sound passage tortuously disposed and with theparts thereof spaced from each other, and a solidified mass of materialin which said assage and the spaced 'parts thereof are em edded.

6. A sound horn having a sound passage tortuously disposed and with theparts thereof spaced from each other, a bell connected to an end of saidpassage, and a solidified mass of material in which said passage and thespace parts thereof and a portion of said bell are embedded.

7. A sound horn having a sound passage composed of a series of hollowmembers,

- said members being embedded in a mass of solidified material andintimately united thereto to form a rigid unit.

8. A sound horn having a sound passage tortuously disposed and with theparts thereof spaced from each other, and a mass of solidified materialfilling the spaces between described and upon said parts and surroundingsaid parts to form a rigid unitary device.

9. A sound horn device comprising a hollow sound member of fibrousmaternal, and a mass of solidified material surrounding and includingsaid member.

10. A sound horn having a hollow sound member, solidified material inwhich said member is embedded, and an envelope for said solidifiedmaterial and embedded member.

11. A sound horn comprising a series of I 13. A sound horn comprising ahollow member adapted for the conveying of sound therethrough, certainportions of said member being substantially straight and other portionsthereof being curved, said curved portions being adapted to reflect thecon veyed sound in said member.

14. A sound horn comprising a series of hollow members, and means forconnecting them to form a tortuous sound conveying passage.

15. A sound horn comprisin a series of tone arm sections arranged to orma tortuous sound conveying passage, and means for holding the large endof a preceding section adjacent the smaller end of a succeeding section.

16. A sound horn comprisin a series of tone arm sections arranged to orma tortuous sound conveying passage, means for holding the large end of apreceding section adjacent the smaller end of a succeeding section, anda bell connected to the large end of the last tone arm section.

17. A sound horn comprising a series of hollow sound conveying members,the ends "of said members being abutted, and means for connecting themembers in series, said members being arranged to form a continuoussound conveying passage.

18. A sound horn comprising a series of hollow sound conveying members,the ends of said members being abutted, and means for connecting themembers in series, said members being arranged to form a continuoustortuous sound conveying passage.

19. A sound horn comprising a series of hollow sound conveying members,the ends of said members being abutted, means for connecting saidmembers in series to form a continuous sound conveying passage, and abell at one end of said passage, and means for joining the bell to saidpassage.

20. A sound horn comprising a series of hollow sound conveying members,the ends of said members being abutted, means for connecting saidmembers in series to form a continuous tortuous sound conveying passage,and a bell at one end of said passage, and means for joining the bell tosaid passa e.

31. A sound horn comprising a series of hollow members, the ends of saidmembers being abutted, and means for connecting them to form a soundconveying passage.

22. A sound horn comprising a series of hollow members, the ends of saidmembers being abutted, and means for connecting them to form a tortuoussound conveying passage.

In witness whereof I hereunto subscribe my name to this specification.

JESSE BARNUM HAWLEY.

